Weighing and Calibration Procedures for Weighlinescaleservice.net/manuals/weightronix/wl_c.pdf · 2...

Weighing and CalibrationProcedures for Weighline

2 Weighing and Calibration Procedures for WeighlineWeigh Bar® is a registered trademark of Weigh-Tronix Inc.

01/20/04 WL_U.P65 PN 29621-0016F e2 Printed in USA

3Weighing and Calibration Procedures for Weighline

Table of Contents

Introduction ..............................................................................................................................5

SETUP Soft Key .............................................................................................................. 5

Manual Entry of Correction Factor ...................................................................................5

ID Soft Key ......................................................................................................................5

Weighing Procedures .................................................................................................................6

Introduction ......................................................................................................................6

Single Scale - Two Draft (Double) Static Weighing System ............................................6

Two Scale Static System - Single or Full Draft Weighing ................................................8

Two Scale Static System - Normal Two Draft Weighing .................................................9

When car trucks are shorter than the center lines of the two scales ....................9

When car trucks are longer than the center lines of the two scales ...................10

Two Scale Static System - Alternative Two Draft Weighing Mode ................................11

Communications ......................................................................................................................12

Appendix 1: Weighline WI-130 Calibration ..............................................................................13

Single and Two Scale Static Systems ...........................................................................13

Step by Step Calibration Procedure ..............................................................................13

Appendix 2: Weighline WI-135 & Model 1310 Calibration .......................................................17

Single and Two Scale Static Systems ...........................................................................17

Step by Step Calibration Procedure ..............................................................................17

Appendix 3

Calibrating Weighline Static Scales when known car weight is not available ................21

Pages are numbered consecutively beginning with the cover page.

4 Weighing and Calibration Procedures for Weighline

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SETUP Soft Key Pressing the SETUP soft key first prompts you for Setpoint #1 value fol-lowed by Setpoint #2 value. You may use this feature by adding OPTOmodules and additional hardware to control filling or loading of cars. Setpointvalues typically are less than system capacity. Reference the ServiceManual for OPTO information and connections to them.

The last prompt under SETUP is for manual entry of Co-factor. This Co-factor or Correction Factor defaults to the value of 1 for each scale. If a Co-factor other than 1 is required, contact customer support at Weigh-Tronix at1-800-458-7062.

Press the ID soft key and the display prompts the operator to enter a sixcharacter identifier. Use either letters or numbers to identify the car beingweighed.

Manual Entry ofCorrection Factor

ID Soft Key

IntroductionYour system can start up in one of two modes:

Mode 1

This mode can be a multi-scale or a single-scale two draft weighing system.The first screen will show these soft keys:

or

Mode 2

This is a multi-scale full draft weighing system. The first screen will showthese soft keys:


Weighing Procedures

Single Scale - Two Draft(Double) StaticWeighing System

Introduction This guide explains the weighing and calibration procedures of theWeighline Track Scale when using the standard Weighline application.

Follow these instructions for two draft, static weighing of a car with a singleWeighline scale.

The following soft keys should be showing:

1. With car clear of scale check thatscale is showing zero weight.Press the ZERO key if it is not. . . Display shows 0.

2. Move the first truck of car ontothe scale and position wheels inthe center of the Weighlinesections. See Figure 1. . . Indicator will display first truck

weight.

Figure 1First truck positioned over scale


Scale should be used in thesame direction as it wascalibrated

3. Press the 1ST key. . . 1ST changes to 2ND. Display willshow approximately twice the firsttruck weight. The first truck weightwill also be displayed in smallercharacters under the main weightdisplay.

4. Move the car so that the secondtruck is on the scale.See Figure 2. . . Total car weight is displayed.

Figure 2Second truck in position over scale

5. Press PRINT to print the weight.

6. Remove car and press the2ND key. . . 2ND changes to 1ST ready to weigh

the first truck of the next car.


Two Scale StaticSystem - Single or FullDraft Weighing

Follow these instructions for two scale, static weighing of a car. See Figure3.


1. With car clear of scale check thatscale is showing zero weight. Ifnot, press the ZERO key. . . The display shows 0.

2. Move the car onto the scale andposition it so that all wheels arein the center of the Weighlinesections. Total car weight is displayed.


4. Remove the car.

Figure 3Two scale static system


Normal Two DraftWeighing - Two ScaleStatic System

When car trucks are shorter than the center lines of the twoscales:The following soft keys should be showing:

1. With car clear of scale check thatscale is showing zero. Press theZERO key if it is not. . . Display shows 0.

2. Move car so that rear truck is onthe first scale and wheelspositioned in the center of theWeighline sections. See Figure 4. Display will show first truck weight.

Figure 4First truck over scale #1

3. Press the 1ST key. 1ST will change to 2ND. Display willshow approximately twice the firsttruck weight. The first truck weightwill also be displayed in smallercharacters under the main Weightdisplay.

4. Press the SCL 1 key. It will change to SCL 2 and weightdisplay will show the first truckweight.

5. Move the car so that secondtruck is on the second scale andwheels are positioned in thecenter of the Weighline sections.See Figure 5. Total car weight is displayed.

Figure 5Second truck over scale #2


If the 1ST softkey says 2ND, justpress that softkey and the namewill change back to 1ST. Thesame is true for the SCL 1/ SCL2 key.

Cars should be weighed in thedirection the scales werecalibrated.

6. Press PRINT to print this weight.

7. Remove the car.

When car trucks are longer than the center lines of the twoscales:


1. With the car clear of the scalecheck that scale is showing zero.

2. Move car so that front truck is onthe second scale and wheelspositioned in the center of theWeighline sections. Indicator will display first truck

weight.

3. Press the 1ST key. . . Soft key display will change to 2NDand display will show approximatelytwice the first truck weight. The firsttruck weight will also be displayed insmaller characters under the mainWeight display.

4. Press the SCL 2 key. Soft key will change to SCL 1 andthe weight will change to the firsttruck weight.

5. Move the car so that the secondtruck is on the first scale and thewheels are positioned in thecenter of the Weighline sections. Total car weight is displayed.

6. Press PRINT to print this weight.

7. Remove the car.


Two Scale StaticSystem - Alternative TwoDraftWeighing Mode

Scale should be used in thesame direction as it wascalibrated

In addition to the normal two scale, two draft weighing mode, either scalemay be used as a single scale for two draft weighing .


or

depending upon the scale selected.

1. With car clear of scale check thatthe scale is showing zero. Pressthe ZERO key if it is not. . . Display shows 0.

2. Move first truck of car onto thescale and position wheels in thecenter of the Weighlinesections. . . Indicator will display the first truck

weight.

3. Press 1ST key. . . Display will change to 2ND. Displaywill show approximately twice thefirst truck weight. The first truckweight will also be displayed insmaller characters under the mainweight display.

4. Move car so that the secondtruck is on the scale. . . Total car weight is displayed.


6. Remove car and press thesoftkey 2ND. . . This will change the soft key to 1ST,

ready to weigh the first truck of thenext car.


Printer output is on COM1: 9600, N, 8, 1Remote display output of total car weight is on COM2: 9600, N, 8, 1

On the 1310, COM3 and COM4 are not used.

Printout from the dual draft mode (mode 1)

DUAL DRAFT12-30-03 14:20:48ID : 1455

TRUCK 1GROSS: 138800 lbTARE : 0 lbNET : 138800 lb

TRUCK 2GROSS: 151800 lbTARE : 0 lbNET : 151800 lb

TOTAL CARGROSS: 290600 lbTARE: 0 lbNET: 290600 lb

Printout from the single draft mode (mode 2)

SINGLE DRAFT12-30-03 14:24:14ID: 123695

TRUCK 1GROSS: 200100 lbTARE: 0 lbNET: 200100 lb

TRUCK 2GROSS: 28500 lbTARE: 0 lbNET: 28500 lb

TOTAL CARGROSS: 228600 lbTARE: 0 lbNET: 228600 lb

Communications


Appendix 1: Weighline WI-130 Calibration

Single and Two ScaleStatic Systems

During the calibration processthe car must be moved acrossthe scale in the direction thescale will normally be used.

Step by StepCalibration Procedure

Indicators used with static Weighline systems are shipped with Weighlinesoftware installed. If software is changed then this software must be in-cluded.

For calibration you need one loaded railroad car with known truck weights.For two scale systems the car truck centers should be the same as willnormally be used.

Each scale has it’s own analog input channel and has effectively two spancalibration values, one for the first truck and one for the second truck. (Thesecond truck calibration value is the first truck calibration factor multiplied bya correction factor.) This is to optimize the performance of the system fortwo draft weighing.

Care should be taken to ensure that the car truck weights do not get re-versed. Refer to Appendix 3 for how to proceed when truck weights are notknown, or if it is not clear which truck weight belongs to which end of thecar, or only a known net weight is available.

1. Enter calibration mode bypressing and holding theESCAPE key until a beep isheard.

2. Key in password (30456) at theSET UP PASSWORD prompt,then press the ENTER key. . . Display shows CAL SCALE # 1.

3. Press ENTER. . . Display shows CALIBRATE with thefollowing soft keys:

4. Press ZERO. . . Display showsZERO CALIBRATIONREMOVE LOAD, PRESS ENTER

5. Make sure scales are clear andthen press ENTER. . . Display shows

DETERMINING ZERO then ...DONEwhen complete. Then (OK) ANYKEY TO CONTINUE.

6. Press any key.

7. Press SPAN. . . Display showsCALIBRATECAL WT (LB):


8. Enter weight of first truck. PressENTER. . . Display shows

SPAN CALIBRATIONAPPLY LOAD, PRESS ENTER

9. Move first truck onto the firstgroup of 4 Weighline scale railsmaking sure that the wheels arein the center of the Weighlinesections.

10. Press ENTER. . . Display showsDETERMINING SPAN........DONE(OK) ANY KEY TO CONTINUE

11. Press any key.

12. Press EXIT. . . Display showsSAVE CHANGES? YES

13. Press YES. . . Display Flashes WEIGH-TRONIXand then showsCAL WT SCL1? (weight entered forfirst truck)

14. Enter second truck weight. PressENTER. . . Display Shows

PLACE CALIBRATION WEIGHTOF“entered weight” ON SCALE 1FOR CALCULATION OF THECORRECTION FACTOR ANDPRESS ANY KEY.

15. Move the car so that the secondtruck is on the first group of 4Weighline scale rails, makingsure that the wheels are in thecenter of the Weighline sections.Press any key. . . Scale now reverts to normal opera-

tion mode.

This completes the calibration for single scale systems. If you have atwo scale system, continue following these steps:

1. On two scale systems re-entercalibration mode again bypressing and holding theESCAPE key until a beep isheard.

2. Key in password (30456) at theSET UP PASSWORD prompt,then press the ENTER key. . . Display shows CAL SCALE # 1.


3. Press the number 2 on thekeypad then press the ENTERkey.

4. Press ENTER. . . Display shows CALIBRATE andthe following soft keys are dis-played:



DETERMINING ZERO ...DONE(when complete)(OK)PRESS ANY KEY TOCONTINUE

7. Press any key.




10. Move car so that the first truck ison the second group of fourWeighlines, making sure that thewheels are in the center of theWeighline sections.

11. Press ENTER. . . Display showsDETERMINING SPAN........DONE(OK) ANY KEY TO CONTINUE.

12. Press any key.



14. Press YES. . . Display flashes WEIGH-TRONIXand then shows CAL WT SCL2?(weight entered for first truck)


PLACE CALIBRATION WEIGHTOF “entered weight” ON SCALE 2FOR CALCULATION OF THECORRECTION FACTOR ANDPRESS ANY KEY.

16. Move the car so that the secondtruck is on the second group offour Weighlines, making sure thatthe wheels are in the center of theWeighline sections.

17. Press any key. . . Scale now reverts to normal opera-tion mode.

This completes the calibration for the two scale system.


Appendix 2: Weighline WPI-135 & Model 1310 Calibration

Single and Two ScaleStatic Systems

During the calibration processthe car must be moved acrossthe scale in the direction thescale will normally be used.

Step by StepCalibration Procedure

Indicators used with static Weighline systems are shipped with Weighlinesoftware installed. If software is changed then this software must be in-cluded.

For calibration you need one loaded railroad car with known truck weights.For two scale systems the car truck centers should be the same as willnormally be used.

Each scale has it’s own analog input channel and has effectively two spancalibration values, one for the first truck and one for the second truck. (Thesecond truck calibration value is the first truck calibration factor multiplied bya correction factor.) This is to optimize the performance of the system fortwo draft weighing.

Care should be taken to ensure that the car truck weights do not get re-versed. Refer to Appendix 3 for how to proceed when truck weights are notknown, or if it is not clear which truck weight belongs to which end of thecar, or only a known net weight is available.

1. Enter calibration mode bypressing and holding theESCAPE key until a beep isheard.

2. Key in password (30456) at theSET UP PASSWORD prompt,then press the ENTER key. . . Display shows CALIBRATE with the

following soft keys:

3. Press CAL. . . Display shows CALIBRATE—CALwith the following soft keys:



DETERMINING ZERO then ...DONEwhen complete. Then (OK) ANYKEY TO CONTINUE.

6. Press any key.





9. Move first truck onto the firstgroup of 4 Weighline scale railsmaking sure that the wheels arein the center of the Weighlinesections.

10. Press ENTER. . . Display showsDETERMINING SPAN........DONE(OK) ANY KEY TO CONTINUE

11. Press any key, then pressESCAPE..


13. Press YES. . . Display Flashes WEIGH-TRONIXand then showsCAL WT SCL1? (weight entered forfirst truck)


PLACE CALIBRATION WEIGHTOF“entered weight” ON SCALE 1FOR CALCULATION OF THECORRECTION FACTOR ANDPRESS ANY KEY.

15. Move the car so that the secondtruck is on the first group of 4Weighline scale rails, makingsure that the wheels are in thecenter of the Weighline sections.Press any key. . . Scale now reverts to normal opera-

tion mode.

This completes the calibration for single scale systems. If you have atwo scale system, continue following these steps:

1. On two scale systems re-entercalibration mode again bypressing and holding theESCAPE key until a beep isheard.

2. Key in password (30456) at theSET UP PASSWORD prompt,then press the ENTER key. . . Display shows the following keys:


3. Press SCL# and key in the number2 on the keypad then press theENTER key. . . Display shows CALIBRATE and

the following soft keys are dis-played:

4. Press CAL. . . Display shows CALIBRATE—CAL and the following keys:



DETERMINING ZERO ...DONE(when complete)(OK)PRESS ANY KEY TOCONTINUE

7. Press any key. . . Display shows CALIBRATE—CAL and the following keys:




10. Move car so that the first truck ison the second group of fourWeighlines, making sure that thewheels are in the center of theWeighline sections.

11. Press ENTER. . . Display showsDETERMINING SPAN........DONE(OK) ANY KEY TO CONTINUE.

12. Press any key, then pressESCAPE.



14. Press YES. . . Display flashes WEIGH-TRONIXand then shows CAL WT SCL2?(weight entered for first truck)


PLACE CALIBRATION WEIGHTOF “entered weight” ON SCALE 2FOR CALCULATION OF THECORRECTION FACTOR ANDPRESS ANY KEY.

16. Move the car so that the secondtruck is on the second group offour Weighlines, making sure thatthe wheels are in the center of theWeighline sections.

17. Press any key. . . Scale now reverts to normal opera-tion mode.

This completes the calibration for the two scale system.


Appendix 3

Calibrating WeighlineStatic Scales whenknown car weight is notavailable

When car truck weights are not known, the first step in calibration should beto set span calibration values of scale 1 to be the same.

Initial Setting of Scale Span Calibration Values

1. Estimate weight of the first truckof the car to be used. This truckweight will be used exclusively.

2. Follow steps 1 through 4 of thecalibration procedure.

3. For step 5 use the default estimatedfirst truck weight rather than thesecond truck weight and do notmove the car - leave the first truckon the scale.

The initial calibration values for scale 1 will now be set.

Total Car Gross Weight is Known

1. Check that soft key displays are as follows and weight display is 0:

2. Place the first truck on thescale. . . Truck weight is displayed

3. Record weight - wt1.

4. Place second truck on scale. . . Second truck weight is displayed -

5. Record weight- wt2.

6. Calculate actual truck weights asfollows:-WT1= Known Gross Weight x {wt1/(wt1+wt2)}WT2= Known Gross Weight x {wt2/(wt1+wt2)}

7. Use the truck weights WT1 andWT2 to calibrate the systemusing the standard procedure.


Net Weight is Known

The painted tare weight of a car is used to do a rough calibration, a knownnet weight is loaded into the car and from this known net weight the grossweight of each truck is calculated. This method is unlikely to be as accurateas having known truck weights

On a full draft two scale system just one of the WEIGHLINE scales is usedto determine the gross weight of each truck.

1. Configure the indicator so that softkey display shows the following:

2. Place the first truck of the emptycar on the scale. . . Truck weight is displayed

3. Record weight - tw1.

4. Place second truck of the empty caron scale Second truck weight is displayed

5. Record weight- tw2.

6. Calculate approximate truckweights as follows:-TW1= Painted Tare Weight x {tw1/(tw1+tw2)}TW2= Painted Tare Weight x {tw2/(tw1+tw2)}

7. Use the truck weights TW1 andTW2 to calibrate the systemusing the standard procedure.

8. Load a known net weight into thecar. Ideally this should be about200,000 lbs. Let this known netweight be:- $NW.

9. Weigh truck #1 on scale 1.Weigh truck #2 on scale 1. Letthese truck weights be:- FW1 and FW2.

10. Calculate the approximate trucknet weights, NW1 and NW2 from:NW1 = (FW1-TW1)NW2 = (FW2-TW2)

11. Calculate the true net weights,$NW1 and $NW2 from:-$NW1 = NW1/(NW1+NW2) * $NW$NW2 = NW2/(NW1+NW2) * $NW

IMPORTANT - to minimizeprocedure errors, ensure thatthe wheels are positioned inthe center of the colored bandfor each and every calibrationweighment.


12. Calculate the correction factor tobe applied to the approximatetare weights, CF1 from:CF1 = $NW1/NW1

13. Calculate the true tare weights,$TW1 and $TW2 from:$TW1 = CF1 * TW1and$TW1 = CF1 * TW2

14. Calculate the true gross truckweights, $GW1 and $GW2 from:$GW1 = $TW1 + $NW1and$GW2 = $TW2 + $NW2

15. Recalibrate the system following thecalibration procedure using$GW1 and $GW2 as the truckweights.

Checking that Car Truck Weights are Correctly Assigned

When car truck weights have been obtained on another scale they some-times get misassigned i.e. recorded truck weights are not associated withthe appropriate car truck. This can cause very confusing results and createthe impression that the indicator is not accepting the truck weights correctlyduring calibration.

The following procedure provides a means of checking that the truckweights are correctly assigned.

1. Configure the indicator so thatthese soft keys are displayed:

2. Place the first truck on the scale. . . Truck weight is displayed

3. Record weight - wt1.

4. Place second truck on scale. . . Second truck weight is displayed

5. Record weight- wt2.

6. Compare wt1 with the knowntruck weight for that truck andwt2 with the known truck weightof that truck.

7. The heaviest actual truck weightshould be the heaviest weightrecorded.

Co-Factor or Correction Factoris entered under the SETUPsoft key menu.

Default = 1 for both scale 1 andscale 2.

Avery Weigh-Tronix Canada, ULC217 Brunswick BoulevardPointe Claire, QC H9R 4R7 CanadaTelephone: 514-695-0380Toll free: 800-561-9461Facsimile: 514-695-6820www.weigh-tronix.ca

Avery Weigh-Tronix1000 Armstrong Dr.Fairmont, MN 56031 USATelephone: 507-238-4461Facsimile: 507-238-4195e-mail: [email protected]

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